Process for flux coating braze preforms and discrete parts

ABSTRACT

Systems and methods for evenly applying a flux coating to any number of different shaped parts with a single machine are described. The systems and methods provide advantages in that the flux coating may be applied accurately within 2% to 4% of desired thickness with 85% to 95% of the total yield of flux being applied, this minimizing waste. Thousands of parts may be batch treated with a single machine without operator input.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Application No. 61/829,109filed May 30, 2013, the entirety of which is herein incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The Field of Invention relates generally to flux and braze alloys, andspecifically to flux coated braze alloy preforms.

2. Discussion of the Related Art

Flux is known in the art of brazing to remove oxides from the parentmetal or alloy part and allow the filler metal to properly bond.Traditionally, flux has been applied to the parent part manually in theform of a paste or liquid just prior to brazing. Over time, variouscompanies have produced filler metals that include a pre-applied flux.These filler metals with included flux eliminate the need for anoperator to manually apply flux.

The manufacture of filler metals with pre-applied flux has been known asan expensive process as waste is often produced. The filler material isoften dipped into a bath of flux which may result in excessive fluxadhering to the filler material. This not only wastes precious fluxmaterial, but also requires extended cleaning operations followingbrazing as the excess flux leaves behind residue or an unsightlyappearance. As the filler metal is immersed in a flux solution, it maycontact other objects and the curing flux may join with the otherobject. Flux may also puddle or run off the part and produce overallinconsistent coatings.

Filler material is also often bent or shaped into various “preforms”such as a wire bent into a ring, helix, triangle, or any other shape.Applying flux to the preform after it is shaped extends the cycle timeof production, while forming the wire into a preform following fluxapplication often results in the flux chipping or cracking.

Additionally, many machines that apply flux to a filler metal or preformare unique to the individual part that is being treated. Oftentimes,expensive dies or machines are custom made for applying flux to a singlepart.

What is therefore needed is a way to apply flux to a filler metal,preform, or any object in a consistent manner. What is also needed is away to apply the flux with minimal material handling. A way to apply aflux coating to any number of differently shaped parts with the samemachine is hereby needed.

SUMMARY AND OBJECTS OF THE INVENTION

A method of applying a flux coating on a plurality of parts for abrazing operation may include tumbling the parts in a tumbling drum witha controlled atmosphere including a user-definable temperature andhumidity within the tumbling drum. The parts may be cycled through acoating cycle within the drum. The cycle may include spraying a fluxfrom at least one nozzle within the tumbling drum while the parts aretumbling for a user-defined period of time. The parts may ultimately becoated with flux with a uniform thickness within 2% to 4% of a desiredthickness.

Following spraying, the parts may be tumbled for an additionaluser-defined period of time to cure the flux to a desired hardness. Thecoating cycle may then be repeated any number of times to build up asufficient coating. The uniform thickness of the coating on the parts isthereby uniformly, incrementally increased with each coating cycle.

An alternative flux coating method for applying a flux coating on aplurality of parts for use for brazing may also include setting theparts on a conveyor that transports the parts into an enclosure with aplasma cleaning chamber to remove contaminants allowing a properadhesion of the flux coating to the parts. The parts may then advance toa heating chamber to heat the parts with infrared light to promotebetter adhesion and curing of the flux. Following heating, the parts mayadvance to an ultrasonic flux spraying chamber where the parts may besprayed with an ultrasonic sprayer configured to atomize a liquid fluxsolution and coat a single side of the parts with the flux coating,leaving an opposing side of the part free of the flux coating.

These and other aspects and objects of the present invention will bebetter appreciated and understood when considered in conjunction withthe following description and the accompanying drawings. It should beunderstood, however, that the following description, while indicatingpreferred embodiments of the present invention, is given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features constituting thepresent invention and of the construction and operation of typicalmechanisms provided with the present invention will become more readilyapparent by referring to the exemplary, and therefore non-limiting,embodiments illustrated in the drawings accompanying and forming a partof this specification, wherein like reference numerals designate thesame elements in the several views, and in which:

FIG. 1 illustrates a perspective view of a drum sprayer;

FIG. 2 illustrates a partial cross sectional view of the drum sprayer ofFIG. 1;

FIG. 3 illustrates a top view of the interior of the drum from the drumsprayer of FIG. 1;

FIG. 4 illustrates a perspective view of an alternative embodiment ofthe drum sprayer of FIG. 1 with dual sprayers;

FIG. 5 illustrates a perspective view of flux coated rings produced withthe drum sprayer of FIG. 1;

FIG. 6 illustrates a side view of an alternative flux coating machine;

FIG. 7 illustrates one embodiment of a preform coated with the inventiveprocess; and

FIG. 8 illustrates one embodiment of a preform coated with the inventiveprocess.

In describing the preferred embodiment of the invention which isillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific terms so selected and it is to be understoodthat each specific term includes all technical equivalents which operatein a similar manner to accomplish a similar purpose. For example, thewords “connected”, “attached”, or terms similar thereto are often used.They are not limited to direct connection but include connection throughother elements where such connection is recognized as being equivalentby those skilled in the art.

DETAILED DESCRIPTION OF EMBODIMENTS

The present invention and the various features and advantageous detailsthereof are explained more fully with reference to the non-limitingembodiments described in detail in the following description.

1. Resume

A process method for Flux Coating Braze preforms and Discrete parts.

A Spray Flux Coating and binder system for coating Braze preform anddiscrete parts.

Process Description:

The process consists of a totally enclosed rotating drum and spraymechanism using controlled heat and positive pressure to efficiently andeconomically flux coat a wide range of Braze preforms and claddeddiscrete parts.

Spray Flux Coating Description:

Spray Flux Coating formulation is designed to operate continuous andintermittent spray processes including fine micro spray systems. Thecoating consists of a compatible braze flux, adhesive resin, and Non VOCsolvent carrier that is sprayed onto braze preforms and functional brazealloy cladded discrete components requiring braze flux. Physicalfunctional properties of the resultant flux coating yields a controlledrange of adhesive strength, durability, hardness, and flexibility tocomply with designated handling requirements for packing and processloading. The operational or duty properties are constant with Flame,Induction, or Controlled atmosphere furnace requirements.

The Flux Coating Process:

-   -   1. Coats a wide size range of multi-dimensional wire forms at a        time.    -   2. Coats a wide size range of multi-dimensional disc forms at a        time.    -   3. Coats wide size range of multi-dimensional shim forms at a        time.    -   4. Coats wide size range of multi-dimensional discrete parts        forms at a time.    -   5. All parts in batch are coated equally dimensionally (tight        tolerances).    -   6. All parts in batch are coated equally by weight (tight        tolerances).    -   7. Process is repeatable.    -   8. Process settings are PLC controlled and stored with optional        infrared sensors (integrated report management).    -   9. Process is temperature and pressure PLC controlled.    -   10. Process is temperature and pressure PLC controlled.    -   11. Process is fluid spray volume is PLC controlled.    -   12. Process RPM is PLC controlled.    -   13. Process drum angle is PLC controlled.    -   14. Process spray pattern is PLC controlled.    -   15. Process internal negative pressure is PLC controlled.    -   16. Process air flow velocity is PLC controlled.    -   17. Spray volumes are recorded and monitored by PLC and        gravimetric scale.    -   18. Provides humidity and temperature control of air.    -   19. Coating fluid can be cooled or heated.    -   20. Exhaust monitoring.    -   21. Solvent-free cleaning capability.    -   22. Process is not operator-dependent once started.    -   23. Process functions can be adjusted at any time during        operation.    -   24. Process is clean to environment.    -   25. Coating yield efficiency is high. Liquid coating is        contained and enclosed. All coating goes on parts other than        fine plume spray that is exhausted.    -   26. Eliminates an alloy material scrap.    -   27. Process provides for quick and easy changeover to other        materials.    -   28. No risk of cross contamination.    -   29. No post heating or curing required.    -   30. Single Load, does not require fixturing or tooling.    -   31. Small footprint.        Flux Coating Claims:    -   1. Less than 50 ppm residual ash content of binder.    -   2. Low temperature decomposition 250-280C.    -   3. Functional in air and controlled atmosphere conditions.    -   4. Coating is hard, durable flexible.    -   5. Functions in Microspray atomization nozzles.

Various manufacturers which produce HVAC components for automotive andcommercial industries are eliminating in-house fluxing systems in favorof pre flux coated parts for improvements to overall cost, quality,output, environmental, and lean initiatives. Though some manufacturersopt to flux coat self-produced parts on site for practical reasons,there is a significant demand to outsource flux coated discrete A1 Cladparts. Improved cost, quality, and versatility may be achieved throughbinder technology and uniqueness of process, i.e., using the tumblingdrum. The binder and process yield precision placement and loading offlux with virtually no waste or byproduct.

2. Detailed Description of Preferred Embodiments

Beginning with FIG. 1, a drum sprayer 10 is shown. The drum sprayer mayinclude any machine configured to tumble parts under a controlledatmosphere and apply a coating. In this embodiment, the drum sprayer 10is a ROTAMAT™ machine manufactured by Walther Trowal. The drum sprayer10 rests on a frame 18 for securing it to the floor. A lid 14 mates withan enclosure 12 to secure the drum 17 during operation, as seen in FIG.2. A handle 28 allows an operator to separate the lid 14 from theenclosure 12 to insert and remove parts from the drum 17. Duringoperation of the drum sprayer 10, the operator may view the progress ofthe parts within the drum 17 through a view port 16.

In order to control the atmosphere within the drum 17, a control panel20 with a series of buttons and a monitor allows an operator toconfigure drum rotation speed and humidity within the drum 17, airtemperature within the drum 17, and the amount of flux sprayed fromnozzle 32, as seen in FIG. 2. Nozzle size is preferable 0.050 in to0.080 in but any spray nozzle size may be used. Exhaust duct 24 may alsobe used to circulate the air within the drum 17 to control theatmosphere. An air inlet hose 22 may also provide air to the drum 17that is conditioned to a desired humidity and temperature.

Following completion of operation, the enclosure 12 and lid 14 may bepivoted about arm pivot 13 allowing an operator to dump the treatedparts into the funnel 31 for collection into a vessel below the funnel31.

Turning now to FIG. 2, a partial cut-away 18 of the drum sprayer isshown. The cut-away 18 exposes the interior of the lid 14 and enclosure12. The interior of the drum 17 is also shown. The cut-away 18 exposesthe contents of the drum 17 during operation wherein a sprayer 32 isactively spraying an atomized flux spray 30 onto brazing parts 34 at apreferred atomizing pressure. During operation of the drum sprayer 10,the drum 17 continuously rotates and agitates the brazing parts 34within. The brazing parts 34 are preferably cleaned of any oils orresidues prior to being placed within the drum 17. While not mandatory,the brazing parts 34 may receive a surface treatment to promote adhesionof the atomized flux spray 30. This ensures proper surface finish andsurface tension. The surface treatment may include simply cleaning theparts as well as adjusting the surface finish and tension through theuse of an abrasive such as an abrasive tumbling machine.

After the brazing parts 34 are inserted into the drum 17, the drumsprayer is activated and the drum begins to rotate and tumble thebrazing parts within. The humidity and temperature within the drum maybe fine tuned to achieve the best adhesion and uniformity of atomizedflux spray 30. The rotational speed of the drum may also be fine tunedto ensure optimal coating.

As the brazing parts 34 are tumbled, the sprayer 32 emits the atomizedflux spray to evenly coat the brazing parts 34 with flux. The exhaustduct 24 draws out any overspray and prevents the atomized flux sprayfrom adhering to the drum 17. The brazing parts 34 are coated with fluxwithin 2% of the desired thickness. For example, if a 0.0050 in coatingof flux is desired, the process is capable of producing a flux coatingbetween 0.0051 in and 0.0049 in evenly and uniformly on hundreds, eventhousands, of parts simultaneously.

Preferably, the sprayer does not spray the entire thickness of desiredflux coating in one spray operation. Optimal results are achieved byspraying multiple coatings with a curing cycle between each spray cycle.The drum continuously rotates, agitating the brazing parts 34 during thecuring cycle, and the sprayer 32 is deactivated. The temperature withinthe drum 17 preferably is 30-50 degrees Celsius; however, it may beadjusted for different flux coatings or different thickness of coatings.Due to the specific mixture of ingredients in the flux, the coatingcures to a sufficient hardness and is durable to remain in tumbling inthe drum without chipping or otherwise damaging the coating of flux. Theflux formulation, including the binder, may also be adjusted fordifferent-shaped parts. Different binders, formulations, and fluxes areshown in the following tables and examples.

As the drum 17 constantly tumbles the brazing parts 34, each part seesthe same amount of spray time from the sprayer 32 and is uniformlycoated. Due to the efficiency of the sprayer and the tumbling operation,85% through 95% of the flux that is sprayed through the sprayer 32 iscoated onto the brazing parts. This prevents waste and reducesmanufacturing costs. Total flux coating time can vary depending on thedesired thickness and the size of the parts to be coated. For example,some batches take as low as 15 minutes while others may take 25 hours.Additionally, once the drum sprayer 10 is loaded and set up, it may rununattended through multiple spray and curing cycles. This reduces laborcosts and allows a single operator to run multiple machines at the sametime.

Moving on to FIG. 3, the interior 38 of the drum 17 may be seen. In thisview, the lid 14 has been removed allowing access to the interior 38.This allows an operator to load and unload brazing parts 34. While thebrazing parts 34 shown in FIG. 3 are brazing caps, virtually any shapedbrazing object may be coated with flux using the drum sprayer 10. Shims,rings, caps, washers, or any other three dimensional shaped part may betreated. Any metal or metal alloy may also be treated. The tumblingaction of the drum ensures a very uniform and even spray of flux. Therepeated curing and spraying cycles while the brazing parts 34 aretumbled ensure the coating is built up gradually and evenly in very fineincrements without puddles or runs in the flux coating. Additionally,agitators 36 help tumble the brazing parts 34 as the drum 17 is rotated.

In order to cut down even further on operator time, FIG. 4 shows anembodiment where multiple sprayers 32 are included inside the drum 17.In this view, the sprayers 32 can be seen in more detail. Spray nozzles42 are adjustable not only directionally, but the spray cone may be finetuned as well. This allows for even more adjustability when differentflux compounds or binders are used. While any spray nozzle 42 size maybe used, ideally 0.050 in to 0.080 in produces optimal results. Hoses 46deliver the flux compound to the sprayers 32. As there are multiplesprayers 32 in this embodiment, each sprayer may be supplied with adifferent flux compound. Having multiple sprayers with differentsolutions allows for cycling the coatings in layers. For example, afirst sprayer 32 could spray a flux compound onto the brazing parts 34for multiple spray and curing cycles. Afterwards, the second sprayer 32could add a sealant, a metal compound, or any other solution. Metal oralloys could be evenly distributed through the sprayer either beforeflux is applied or after. Really, any combination of flux, metals,alloys, solutions, treatments could be applied in whatever interval orcycle desired. This may all be done automatically without an operatorinterrupting the drum sprayer 10, as the hoses 46 may be supplied withdifferent storage vessels of any desired compound. As different fluxsolutions may be applied using the same drum sprayer 10, the hoses 46and sprayers 32 may be purged in as little as 25 to 30 minutes.

FIG. 5 shows flux coated brazing rings 48 that have been treated withthe drum sprayer 10. As can be seen, the flux is sprayed on very evenlyand does not produce any runs or sticking of parts. Using many spraycycles that are followed by curing cycles all under a controlledatmosphere with user-programmable temperature and humidity produce thedesired flux coating within 2% through 4% of the target thickness.Optionally, a recovery system may be installed with the exhaust 24 ofthe drum sprayer 10. A filter may also be used in the exhaust tominimize floating particulates as well as for recovery. This allows fora clean operation. The recovery system may capture the minimal atomizedflux spray 30 that does not adhere to the brazing parts 34 andreintroduce the recovered flux into the stored flux solution that isapplied by the sprayer 32. This would allow the standard yield of fluxcoating used 85% to 95% to be increased even higher.

An alternate embodiment of the invention may be seen in FIG. 6. Theunique combination of binders and additives with the flux, as shown inthe tables and examples below, produces a much more resilient fluxcoating that enables the use of other non-traditional manufacturingmethods. For example, continuous application of flux to a single side ofparts is enabled by the conveyor coater 49. A belt 50 continuouslyrotates through an enclosure 51 which is normally fully enclosed, exceptfor an entrance port 53 and an exit port 55 that allows parts to enterand exit the enclosure 51. Untreated parts 52, such as manifold headers,may be placed on the belt 50 and enter the enclosure 51 at the entranceport 53. Inside the enclosure 51, it is divided into multiplecompartments. A plasma cleaning compartment 54 thoroughly cleanses theuntreated parts 52 to remove any contaminants, oils, or debris. Theplasma cleaner 60 emits plasma 62 for proper cleaning. The belt 50 thenadvances the pats into a heating chamber 56. While any source of heatmay be used, preferably infrared lamps 64 are used to emit infraredradiation 66 to heat the parts to the desired temperature. The heatsource may be controlled as well as the speed of the belt 50 to properlyachieve the desired temperature. Once the parts are at the desiredtemperature they may advance to the flux spraying chamber 58. A sprayhead 68 ultrasonically sprays a flux coating 70 to the parts. As theparts are lying on the belt 50, only a single side of the parts issprayed with the flux coating 70. The spray head 68 may be located in adesired configuration to direct the flux coating where it is needed. Theparts may also be located on the belt 50 in such as manner that only thedesired area of the parts are sprayed with the flux coating 70.Additionally, the spray head 68 may be dynamically controlled andprogrammed to move as it applies the flux spray 70, similar to a roboticarm positioning a welder when welding seams on a vehicle chassis. Thefinal product is a flux coated part 72 that is ready for brazing withapplication of any additional flux.

The conveyor coater 49 allows for a part itself to be prepped for flux,and have flux applied directly to the part. This eliminates the need toapply any flux at all during assembly and manufacturing. Traditionally,flux is applied with a brush just prior to brazing. Alternatively, fluxmay be included inside the filler wire or coated on the filler wire.Either way, the flux must be applied at the brazing site. The conveyorcoater 49 allows for batch treatment of many different parts of anysize/dimension. The spray head may be located, or programmed to move, tothe desired area and only spot-treat the desired areas with a fluxcoating. Additionally, multiple spray heads may be included to sprayadditional coatings. Metals or alloys may also be sprayed to eliminatethe need for filler metals to be applied at the brazing site. There isno limitation on how many chambers the enclosure may include or howlarge the enclosure may be. Similarly, the parts do not necessarily needto be cleaned with the plasma cleaner 60 or heated with the infraredlamps 64. Any effective cleaning apparatus or heating apparatus mayalternatively be used.

Looking at FIGS. 7 and 8, one embodiment of a preform is shown coatedwith the inventive coating and inventive process. FIGS. 7 and 8 alsoindicate the tight tolerance the coating procedure produces and itsability to consistently apply a very controlled, uniform coating.

Specific embodiments of the present invention will now be furtherdescribed by the following, non-limiting examples which will serve toillustrate various features of significance. The examples are intendedmerely to facilitate an understanding of ways in which the presentinvention may be practiced and to further enable those of skill in theart to practice the present invention. Accordingly, the examples shouldnot be construed as limiting the scope of the present invention.

TABLES CUSTOMER Date: Mar. 25, 2013 ALLOY: 32-380 form 83 coated STARTSIZE .028″× .128″ COATED SIZE .031″ × .120″ +/− .002 JOB NUMBER: 918683COATING TYPE (ID & C0DE) code 84-413 SURFACING solvent clean/38 Dynewettability COATING LOT NUMBER X6950 COATING START WEIGHT 2541 gramsALLOY START QTY 10000 ALLOY LOT NUMBER 251370/244518 ALLOY BULK WEIGHT909 grams ALLOY PIECE WEIGHT .0911 grms (average) TARGET COATED BULKWEIGHT 988.03 grams TARGET COATED PIECE WEIGHT .09902 grams TARGETCOATED THICKNESS/ID 0.031″ × .120″ ID +/− .002″ PROCESS LOCATION/MACHINEID COATING PROCESS OPERATOR (S) COATING VOLUME/GRAMS/HOUR 251 COATINGAPPLICATOR TYPE Rotamat COATING SPRAY GUN SETTINGS 5 clicks PROCESSTEMPERATURE 30 C. DRUM ANGLE & SPEED 10 rpm PROCESS START TIME/DATE10:25A:00 AM/3/25/2013 PROCESS END TIME/DATE 12:05 PM 2/13/13. COATINGQTY USED 821 gr. TOTAL PROCESS TIME 3 hr. 16 min. COATED BULK WEIGHT993.1 grms COATED PIECE WEIGHT .0995 gr FLUX PERCENT 6.33% BINDERPERCENT 2.11% TARGET FLUX COVERAGE (g/m{circumflex over ( )}2) FLUXCOVERAGE (g/m{circumflex over ( )}2) COATED THICKNESS: .031″ COATED ID.118 to .120 COATED OD .190″ COATING/ALLOY SCRAP QTY: 60% Coating scrapPERCENT YIELD OF COATING ALLOY: 40% SPECIALNOTES/COMMENTS/RECOMMENDATIONS: Increases flux content to 18% resultedin heavy cob webbing and coating loss. This also added to processingtime. Suggest original formula w/ 9% flux for next test.

EXAMPLES Flux Coating Identification

FORMULA #8 REV 2

X6857

Alloy Code: 84-413

Description:

UT/ROTAMAT™ and spray gun compatible flux coating solution for applyinga durable coating of flux loadings up to 0.015″ for hi-temp alloy brazewashers. Surface enhancement is required for adhesion.

Formulation from Sub-Assembly Base:

-   -   1. DMC (80-027) dimethyl carbonate=52%    -   2. BINDER BASE X6848 (20% concentration elvacite (iso-butyl        methacrylate polymer) 80% DMC)=15.0%    -   3. BINDER BASE X6849 (20% concentration polyethylene carbonate        80% DMC)=15.0%    -   4. Lucas Milhaupt™ 1166A Flux (82-092) −325 mesh=18%        Formulation Constituents:    -   1. DMC (80-027)=76%    -   2. Lucas Milhaupt™ 82-092 Flux −325 mesh=18%    -   3. BINDER RESIN (80-198) (elvacite 2045(iso-butyl methacrylate        polymer), which is an acrylic resin)=3.0%    -   4. BINDER RESIN (80-215) (polyethylene carbonate)=3.0%        Procedure:        Equipment:    -   1. Polyethylene or Chemical Resistant Mixing Container with Lid.        (×2)    -   2. Container lid w/slot for mixing blade.    -   3. Variable Speed Air Mixer    -   4. Dispersion Mixing Blade    -   5. Scale Capable to 5000 grams Capacity and to 0.01 grams        Sensitivity    -   6. Paint filter    -   7. Chemical Resistant hand Stirrers and Spatulas/Scoops/Measure        Containers.        Mixing Instructions:    -   1. In designated mixing container, weigh 15% Batch weight of        Binder Base X6848    -   2. In designated mixing container, weigh 15% Batch weight of        Binder Base X6849    -   3. In designated mixing container, weigh 52% Batch weight of DMC        (80-027);    -   4. Mount mix to air operated mixer affixed with dispersion        mixing blade through slotted lid/    -   5. In Designated Container, weigh 18.0% 166A (82-092)Flux −325        mesh    -   6. With slotted lid in place, Mix vigorously to disperse all        flux particles into solution, eliminating agglomerates    -   7. Remove from Mixer and filter through paint filter to screen        any debris or larger particles. (Stir or aid with spatula as        needed. *** If excessive flux particles are filtered or settle        to bottom of mix (0.5%), dry and weigh the flux, then add same        weight of 1166A flux to mix. Then filter again.    -   8. Label with Product ID and Batch Number        Special Notes:    -   1. Mix in well ventilated area.    -   2. Keep mix covered at all times possible to prevent evaporation        or contamination    -   3. All handling equipment is to be free of foreign matter, dust,        oil; moisture.    -   4. Keep away from excessive heat or open flame.        “Flux Coating Identification”:        FORMULA #4 REV 3        Alloy Code: 84-407        Description:        UT/ROTAMA™ and spray gun compatible flux coating solution for        applying a durable (light adhesive) coating of flux loadings for        controlled atmosphere furnace brazing of aluminum alloy clad        parts. Coating is suitable for enclosed or trapped areas.        Surface enhancement is required for adhesion.        Formulation from Sub-Assembly Base:    -   5. DMC (80-027) (dimethyl carbonate)=81%    -   6. BINDER BASE Q (81-089)=11.25%    -   7. NOCOLOK® FLUX (82-033)=7.75%        Formulation Constituents:    -   5. DMC (80-027)=90%    -   6. NOCOLOK® FLUX (82-033, potassium aluminum fluoride)=7.75%    -   7. BINDER RESIN (80-215)=2.25%

What is claimed is:
 1. A method of applying a brazing flux coating on aplurality of parts for a brazing operation comprising: preparing theplurality of parts from a metal alloy into a preform in the shape of atleast one of a ring, helix, triangle, and other geometric shape;preparing the flux coating while preventing airborne humidity from beingabsorbed by the flux coating; adding an acrylic resin binder to the fluxcoating; tumbling the parts in a tumbling drum with a controlledatmosphere including a user definable temperature and humidity withinthe tumbling drum; cycling the parts through a coating cycle comprising:spraying the brazing flux coating from at least one nozzle within thetumbling drum during the tumbling for a user defined period of time;coating the parts with the brazing flux coating with a uniform thicknessof up to 0.015 in (0.381 mm), wherein the brazing flux coating isconfigured to melt and separate from the preform during the brazingoperation; tumbling the parts following the user defined period of timeto cure the brazing flux to a desired hardness; and repeating thecoating cycle for a plurality of repetitions wherein the uniformthickness of brazing flux coating on the parts is uniformly increasedwith each coating cycle.
 2. The method of applying a brazing fluxcoating on a plurality of parts for a brazing operation of claim 1,further comprising adding an iso-butyl methacrylate polymer to thebrazing flux coating.
 3. The method of applying a brazing flux coatingon a plurality of parts for a brazing operation of claim 2, furthercomprising mixing polyethylene carbonate with the binder.
 4. The methodof applying a brazing flux coating on a plurality of parts for a brazingoperation of claim 1, further comprising coating the parts with thebrazing flux while maintaining a coated weight of the part within 2% ofan uncoated weight of the part.
 5. The method of applying a brazing fluxcoating on a plurality of parts for a brazing operation of claim 1,further comprising spraying the flux from a nozzle with an opening fromwhich the coating exits having an internal diameter of 0.05 in (1.27 mm)to 0.08 in (2.032 mm).
 6. The method of applying a brazing flux coatingon a plurality of parts for a brazing operation of claim 1, furthercomprising circulating the atmosphere within the tumbling drum withexhaust ducts.
 7. The method of applying a brazing flux coating on aplurality of parts for a brazing operation of claim 1, furthercomprising adhering 85% to 95% of the sprayed brazing flux to the parts.8. The method of applying a brazing flux coating on a plurality of partsfor a brazing operation of claim 1, further comprising: agitating theparts within the drum with at least one agitator during tumbling;keeping the brazing flux coating covered prior to use in the tumblingdrum to prevent evaporation or contamination of the brazing fluxcoating; and maintaining the tumbling drum and the brazing flux coatingfree of a foreign matter, a dust, an oil, and a moisture prior to use inthe tumbling drum.
 9. The method of applying a brazing flux coating on aplurality of parts for a brazing operation of claim 1, furthercomprising spraying a sealant over the parts and brazing flux.
 10. Themethod of applying a brazing flux coating on a plurality of parts for abrazing operation of claim 1, further comprising setting the parts on aconveyor that transports the parts into an enclosure with a plasmacleaning chamber, a heating chamber, and an ultrasonic brazing fluxspraying chamber.
 11. The method of applying a brazing flux coating on aplurality of parts for a brazing operation of claim 10, furthercomprising plasma cleaning the parts in the plasma cleaning chamber toremove contaminants allowing a proper adhesion of the brazing fluxcoating to the parts.
 12. The method of applying a brazing flux coatingon a plurality of parts for a brazing operation of claim 11, furthercomprising heating the parts after plasma cleaning in the heatingchamber to a desired temperature.
 13. The method of applying a brazingflux coating on a plurality of parts for a brazing operation of claim12, further comprising spraying the parts after heating with anultrasonic sprayer configured to atomize a liquid brazing flux solutionand coat a single side of the parts with the brazing flux coating andleaving an opposing side of the part free of the brazing flux coating.14. The method of applying a brazing flux coating on a plurality ofparts for a brazing operation of claim 10, further comprising adjustinga speed of the conveyor to dry the parts to a desired moisture content.15. The method of applying a brazing flux coating on a plurality ofparts for a brazing operation of claim 1, further comprising sprayingone of a metal and an alloy on the brazing flux coated parts, thuseliminating a need for an additional subsequent filler metal applicationduring a brazing procedure.
 16. The method of applying a brazing fluxcoating on a plurality of parts for a brazing operation of claim 1,wherein the uniform thickness of the brazing flux coating on the partsis within 2% of a desired thickness.
 17. The method of applying abrazing flux coating on a plurality of parts for a brazing operation ofclaim 1, further comprising: preparing the brazing flux coating bymixing dimethyl carbonate, a binder, and a flux followed by filteringthe brazing flux coating with a filter size of 325 mesh or smaller;preventing a moisture from ambient air from being absorbed by thebrazing flux coating by sealing the flux coating at all times prior tothe spraying; cleaning the parts free of any oils or residues prior tothe coating; adjusting a spray nozzle opening size to 0.050 in to 0.080in; adhering 85% through 95% of the sprayed brazing flux coating to theparts; and coating the parts within 2% of a desired brazing flux coatingthickness.
 18. A method of applying a brazing flux coating on aplurality of parts for a brazing operation comprising: preparing theplurality of parts from a metal alloy into a preform in the shape of atleast one of a ring, helix, triangle, and other geometric shape; addingan acrylic resin binder to the flux coating; preventing a moisture fromambient air from being absorbed by the flux coating by sealing the fluxcoating at all times prior to a spraying operation; maintaining thebrazing flux coating in a moisture-free environment prior toapplication; spraying the brazing flux coating from at least one nozzlewithin a tumbling drum during a tumbling operation for a user definedperiod of time; maintaining a moisture and temperature level within thetumbling drum at a predetermined level; coating the parts with thesprayed brazing flux with a uniform thickness up to 0.015 in (0.381 mm)thick while maintaining the coating thickness within a 2% deviation of atargeted thickness, wherein the brazing flux coating is configured tomelt and separate from the preform during the brazing operation;tumbling the parts following the user defined period of time; and curingthe brazing flux to a desired hardness within the tumbling drum with themaintained moisture and temperature level.
 19. The method of applying abrazing flux coating on a plurality of parts for a brazing operation ofclaim 17, further comprising: mixing an iso-butyl methacrylate polymerwith the brazing flux; and mixing a polyethylene carbonate with thebinder.
 20. A method of applying a brazing flux coating on a pluralityof parts comprising: preparing the plurality of parts from a metal alloyinto a preform in the shape of at least one of a ring, helix, triangle,and other geometric shape; adding an acrylic resin binder to the fluxcoating; preventing a moisture from ambient air from being absorbed bythe flux coating by sealing the flux coating at all times prior to aspraying operation; spraying the brazing flux from at least one nozzlewith an opening of 0.05 in (1.27 mm) to 0.08 in (2.032 mm); tumbling theparts for a user defined period of time within a tumbling drum; coatingthe parts with the sprayed brazing flux to a uniform thickness, whereinthe brazing flux coating is configured to melt and separate from thepreform during the brazing operation; curing the brazing flux to adesired hardness by circulating an atmosphere within the tumbling drumwith exhaust ducts; maintaining the uniform thickness within at leastone of 2% of a desired thickness; and adhering 85% to 95% of the sprayedflux to the parts.